Internal park brake system, apparatus, and method

ABSTRACT

A park brake system for an electric motor actuator is provided. The system may comprise a micro-motor, and one or more gears. The system may be configured to exert a radial force on a shaft of the electric motor actuator to lock the actuator. Moreover, in various embodiments, the system may be bi-stable.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional application of and claims priority to,U.S. patent application Ser. No. 13/930,391, entitled “INTERNAL PARKBRAKE SYSTEM, APPARATUS, AND METHOD,” filed Jun. 28, 2013, which isherein incorporated by reference in its entirety.

FIELD

The present disclosure relates to braking systems and, morespecifically, to a stable (e.g., mono-stable and/or bi-stable) parkbrake for use with an electro-mechanical braking system.

BACKGROUND

Typical park brakes or friction brakes consist of a friction disc, whichis clamped via a spring between the brake housing and a steel armatureplate. The armature plate can be manipulated by providing an electricalcurrent pulse to an electro-magnet and permanent magnet assembly inorder to either attract and hold the armature plate away from thefriction disc (free state), or, after reversal of the current pulse,release the armature plate and clamp the friction disc (locked state).These systems may be susceptible to wear, vibration and/or contaminationthat could contaminate the internal structures of the electric motoractuator.

SUMMARY

In various embodiments, a park brake may comprise a micro-motor, a firstgear, and a second gear. The micro-motor may comprise a gear train. Thefirst gear may be coupled to the micro-motor. The second gear may becoupled to a shaft. The first gear may be configured to operativelyengage the second gear, such that the shaft may bind and/or wedge inresponse to the motor being energized.

In various embodiments, an electric motor actuator may comprise anelectric motor, a shaft, a sector gear, a micro motor, and a piniongear. The shaft may be coupled to the electric motor. The sector gearmay be coupled to the shaft. The pinion gear may be coupled to themicro-motor. The pinion gear may be configured to operatively engage thesector gear.

In various embodiments, an electric motor actuator may comprise a shaft,a shaft support, a first gear, a second gear, and a micro-motor. Theshaft may be installed within the shaft support. The first gear may beinstalled on the shaft. The second gear may be configured to operativelyengage the first gear. The motor may be configured to drive the secondgear, such that, in response to the motor being energized, the secondgear may drive the first gear causing the shaft to bind with the shaftsupport.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements.

FIG. 1 illustrates an exploded perspective view of an electric motoractuator in accordance with various embodiments.

FIG. 2A illustrates a first cross-sectional view of a portion of anelectric motor actuator in accordance with various embodiments.

FIG. 2B illustrates a second cross-sectional view of a portion of anelectric motor actuator in accordance with various embodiments.

FIG. 2C illustrates a third cross-sectional view of a portion of anelectric motor actuator in accordance with various embodiments.

FIG. 2D is a block diagram that illustrates components of an exemplarymicro-motor in accordance with various embodiments.

FIG. 3 illustrates a cross-sectional view of a portion of an electricmotor actuator comprising a wrap spring in accordance with variousembodiments.

FIG. 4 is a block diagram that illustrates a method of operating anelectric motor actuator in accordance with various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration and their best mode. While these exemplary embodiments aredescribed in sufficient detail to enable those skilled in the art topractice the inventions, it should be understood that other embodimentsmay be realized and that logical, chemical and mechanical changes may bemade without departing from the spirit and scope of the disclosure.Thus, the detailed description herein is presented for purposes ofillustration only and not of limitation. For example, the steps recitedin any of the method or process descriptions may be executed in anyorder and are not necessarily limited to the order presented.

Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Also, any reference to attached, fixed, connected orthe like may include permanent, removable, temporary, partial, fulland/or any other possible attachment option. Additionally, any referenceto without contact (or similar phrases) may also include reduced contactor minimal contact.

As used herein, phrases such as “make contact with,” “coupled to,”“touch,” “interface with” and “engage” may be used interchangeably.Different cross-hatching may be used throughout the figures to denotedifferent parts, but not necessarily to denote the same or differentmaterials.

In various embodiments, a brake system may comprise an electric motoractuator (“EMA”). The EMA may be coupled to or otherwise operate apressure generating device such as, for example, a ball screw, a ram,and/or the like. In operation, the EMA may cause the pressure generatingdevice to move and/or exert a force on other brake system structuressuch as, for example, a brake disk or pad to exert a stopping force on awheel or other suitable moving structure. The brake system may alsoinclude a park brake feature.

The park brake feature may be used to reduce the load on the EMA whenthe brake is engaged (e.g., in an idle configuration while waiting fortake-off). The park brake feature may also provide brake lockingcapability, when power is not available to maintain power to the EMA(e.g., in a parked configuration).

In various embodiments, and with reference to FIG. 1, EMA 10 maycomprise a housing 12 and a cover 30. A three dimensional x, y and zaxes is shown for reference and to aid in description. Cover 30 may beconfigured to sleeve over and/or couple to housing 12. EMA 10 mayfurther comprise a park brake assembly 20 that is installable withinhousing 12. EMA 10 may also comprise a motor 14 and a shaft 16. Parkbrake assembly 20 may comprise a pinion gear 22 and a sector gear 26.Park brake assembly 20 may couple to or install on shaft 16. Morespecifically, sector gear 26 of park brake assembly 20 may operativelycouple to or otherwise attach to sector gear 26.

In various embodiments, FIGS. 2A-2D show various cross sectional viewsof a portion of an EMA 10, where the x and y axes are shown forreference. Shaft 16 may be coupled to and/or combined with an electricmotor 14. Electric motor 14 may turn and/or drive shaft 16. Shaft 16 maybe coupled to or be integrally formed with a ball screw and/or othersuitable ram. In this regard, shaft 16 is configured to translate therotational motion of electric motor 14 to linear motion through the ballscrew to create pressure on a stopping mechanism (e.g., a brake pad,pressure plate, wheel hub, and/or the like).

In various embodiments, pinion gear 22 may be configured to engageand/or operatively couple to sector gear 26, as shown in FIG. 2B. Piniongear 22 may also be configured to drive sector gear 26 underpre-determined or dynamically determined operating conditions. Piniongear 22 may be coupled to a micro-motor 24, as shown in FIG. 2C.

Motor 24 may be any suitable motor including, for example, amicro-motor. Motor 24 may provide a high mechanical advantage in arelatively small package to fit with a small envelope package of EMA 10.Motor 24 may comprise a gear train 25 (e.g., a micro-gear train withinthe housing of motor 24), and shown in FIG. 2D. Gear train 25 may have agear ratio of approximately 35:1 to 90:1. The gear train of micro-motormotor 24 may also engage or be coupled to pinion gear 22. Pinion gear 22provides an additional gear ratio of approximately 2:1 to 5:1 withrespect to sector gear 26.

In various embodiments, sector gear 26 may be any suitable eccentricgear. In this regard, sector gear 26 may have a variable radius. In thisregard, sector gear 26 is eccentric to the centerline of the shaft 16(e.g., axis X). More specifically and with particular reference to FIG.2B, sector gear 26 may be a portion of a gear wheel (e.g., a gear havinga pie shape) having a first end A and a second end B. Moreover, theprofile defined by the portion of the gear wheel may be non-uniform(e.g., having a first radius associated with first end A and a secondradius associated with second end B, where the first radius is shorterthan the second radius). In this regard, a profile C of the gear may benon-uniform and/or have a curvature that is a portion of an ellipse, butthat would not be a portion of a circle. Moreover, sector gear 26 maycomprise teeth over the portion of the non-uniform profile between thefirst end and the second end.

In various embodiments, EMA 10 may be locked under certain aircraftoperating conditions (e.g., pre-determined operating conditions and/ordynamically determined operating conditions). In response to a commandor condition to lock EMA 10, park brake assembly 20 may be engaged. Forexample, motor 24 may drive pinion gear 22 causing sector gear 26 torotate along its non-uniform profile. The eccentric shape of sector gear26 may act like a cam that creates a bind on the shaft 16. In thisregard, as pinion gear 22 rotates the sector gear 26 between the firstradius and the second radius, the body of sector gear 26 exerts a radialforce (e.g., a force perpendicular to the X-axis) on shaft 16. This maycause shaft 16 to push into and/or bind on an internal structure of EMA10 such as, for example, a shaft support 27 and/or an eccentric bushing28.

In various embodiments and with reference to FIG. 3, EMA 10 may comprisea wrap spring 29. In this regard, EMA 10 and, more specifically shaft16, may be locked by wrap spring 29. For example, wrap spring 29 may beinstallable over shaft 16 (e.g., wrap spring 29 defines a channel thatshaft 16 may install through. Further, a first end of wrap spring 29 maybe coupled to a stationary structure or EMA 10 (e.g., a portion of ahousing 11). A second end of wrap spring 29 may be coupled to and/orengage sector gear 26. In this regard, as sector gear 26 rotates to lockEMA 10, wrap spring 29 would tighten on shaft 16, causing shaft 16 tobind.

In various embodiments, spring 29 may be fabricated from any suitablematerial such as, for example, round or square spring wire or bemachined from solid bar stock, or molded from plastic material. Thematerial of spring 29 may be chosen to achieve corrosion resistance(e.g., stainless steel) and sustain its properties over a broadtemperature range, such as, for example, temperature from approximately−65° F. to approximately 350° F. In various embodiments, the gear ratioof park brake assembly 20 (e.g., the gear ratio associated with the geartrain of motor 24 and pinion gear 22 relative to sector gear 26) mayminimize the ability of EMA 10 and, more specifically, electric motor 14to back-drive sector gear 26, under normal operation conditions. In thisregard, park brake assembly 20 may lock EMA 10. The use of high gearratios described above tend to create high levels of reflected inertia,which in turn reduces the ability of electric motor 14 to back drivesector gear 26.

In various embodiments, motor 24 may be bi-directional. Motor 24 mayalso have infinite rotation capability in both directions (e.g.,clockwise and counter clockwise rotation), unlike solenoid based devicesthat have limited translations. The infinite rotation may allow forincreased clamping adjustment as park brake assembly 20 componentsand/or other components wear (e.g., pinion gear 22, sector gear 26,eccentric bushing 28, pressure plates, brake pads, and/or other suitablecomponents).

In various embodiments, contact force on shaft 16 may be increased withadditional rotation, because park brake assembly 20 and, morespecifically, pinion gear 22 and motor 24 have unlimited degrees offreedom in the rotary direction. The demand for increase friction forcemay be due to vibration, friction coefficient reductions, or componentwear.

In various embodiments, pinion gear 22, motor 24 and sector gear 26 mayprevent shaft movement in the applied or released condition creating adesired bi-stable condition. For example, in response to an input tolock EMA 10, motor 24 may be energized and cause pinion gear 22 andsector gear 26 to rotate to bind shaft 16. In response to the bindcondition, motor 24 may be de-energized and still maintain EMA 10 in alocked condition. This is possible due to gear ratio provided by thesystem. Moreover, as a safety feature, EMA 10 and, more specifically,electric motor 14 has the capability to overcome a locked condition,because the output of EMA 10 at above normal operating conditions isable to overcome the reflected inertia associated with the gear ratioassociated with park brake assembly 20.

In various embodiments, park brake assembly 20 may be controlled by orin electronic communication with a suitable control unit. The controlunit may be capable of monitoring brake and/or EMA 10 operation. Thecontrol unit may further comprise logic that is configured to reduce theload on EMA 10 during operation. For example, the control unit may beconfigured to monitor a time associated with a load on EMA 10. Inresponse to an electrical load exceeding a pre-determined threshold(e.g., 20 seconds) the control unit may activate or engage park brakeassembly 20 to lock EMA 10 and minimize the electrical load on EMA 10.This condition may occur during taxi, as the aircraft is preparing totake off, or as the aircraft is moving about the airport (e.g., movingto a gate to boarding or deplaning, moving to a maintenance area, and/orthe like).

In various embodiments and with reference to FIG. 4, the control unitmay be configured to monitor and control EMA 10. For example, a bindingmechanism (e.g., park brake assembly 20) may be kept disengaged from theshaft and the EMA may produce the requested load on the brake system(Step 410). In response to the EMA being commanded to maintain apre-selected load and/or duration, the micro-motor of the park brakeassembly may be activated to cause the binding mechanism to bind, wedge,and/or hold the shaft (Step 420). In this regard, the control unit maybe configured to monitor the load on the EMA and engage the park brakeassembly in response to the load exceeding a predetermined threshold. Byreducing the load with the activation of the park brake assembly, theoperational stress of associated with EMA operation (e.g., heat) may bereduced on various EMA components (e.g., the EMA motor, EMA gears,and/or the like). The EMA may be de-energized and the retained EMA loadmay be transferred from the motor assembly to the binding mechanism(Step 430). By transferring the load, the binding mechanism, and morespecifically, the gear train of the park brake assembly carry the loadrequired to hold the position of the EMA. In response to a command todisengage the park brake, the micro-motor of the park brake assembly maybe activated to disengage the binding mechanism from the shaft allowingthe EMA to control the load on the brake system (Step 440).

In various embodiments, park brake assembly 20 may be engaged to hold avehicle (e.g., an aircraft in a stationary position when the aircraft isat rest (e.g., during overnight storage). Park brake assembly 20 may beengaged to hold a vehicle stationary during a start, warm-up, inspectionor service. Park brake assembly 20 may also be engaged during flight inan aircraft application to avoid vibrational wear to EMA 10 and/or otherbrake system components.

The park brake assemblies described herein provide a cost effective,reliable, bi-stable locking system for electric motor actuators. Parkbrake assembly 20 may provide overall cost savings as compared totypical park brake systems. Moreover, the park brake assembly 20 mayoccupy substantially the same size envelope and mass of typical parkbrake systems.

In various embodiments, while the park brake assemblies described hereinhave been described in the context of aircraft applications, one willappreciate in light of the present disclosure, that the park brakeassemblies described herein may be used on various other items that usea park brake including vehicles such as, for example, trains. Moreover,the park brake assemblies described herein may be employed with anysuitable electric motor actuator in any installation to create abi-stable locked condition.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the inventions. The scope of the inventions is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” is usedin the claims, it is intended that the phrase be interpreted to meanthat A alone may be present in an embodiment, B alone may be present inan embodiment, C alone may be present in an embodiment, or that anycombination of the elements A, B and C may be present in a singleembodiment; for example, A and B, A and C, B and C, or A and B and C.Different cross-hatching is used throughout the figures to denotedifferent parts but not necessarily to denote the same or differentmaterials.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “one embodiment”, “an embodiment”, “anexample embodiment”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed. After reading the description, it will be apparent to oneskilled in the relevant art(s) how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112, sixth paragraph, unless the element isexpressly recited using the phrase “means for.” As used herein, theterms “comprises”, “comprising”, or any other variation thereof, areintended to cover a non-exclusive inclusion, such that a process,method, article, or apparatus that comprises a list of elements does notinclude only those elements but may include other elements not expresslylisted or inherent to such process, method, article, or apparatus.

What is claimed is:
 1. A park brake, comprising: a micro-motorcomprising a gear train; a first gear coupled to the micro-motor; asecond gear coupled to a shaft, the first gear configured to operativelyengage the second gear, wherein the shaft binds in response to themicro-motor being energized.
 2. The park brake of claim 1, wherein thefirst gear is a pinion gear and the second gear is a sector gear.
 3. Thepark brake of claim 1, wherein the second gear is a sector gearcomprising a non-uniform radius.
 4. The park brake of claim 1, whereinthe shaft is a portion of an electric motor actuator.
 5. The park brakeof claim 4, wherein the shaft is installed in an eccentric bushing. 6.The park brake of claim 5, wherein the shaft binds in the eccentricbushing in response to the micro-motor being energized.
 7. The parkbrake of claim 1 further comprising a wrap spring installable over theshaft and coupled to the second gear.
 8. The park brake of claim 7,wherein the shaft is constrained by the wrap spring in response to themicro-motor being energized.
 9. The park brake of claim 1, wherein themicro-motor is automatically energized in response to a pre-determinedcondition.
 10. An electric motor actuator, comprising: an electricmotor; a shaft coupled to the electric motor a sector gear coupled tothe shaft; a micro-motor; a pinion gear coupled to the micro-motor, thepinion gear configured to operatively engage the sector gear.
 11. Theelectric motor actuator of claim 10, wherein the sector gear comprises anon-uniform profile.
 12. The electric motor actuator of claim 11,wherein the sector gear is configured to exert a force on the shaft inresponse to the micro-motor being energized.
 13. The electric motoractuator of claim 10, further comprising a wrap spring installable onthe shaft.
 14. The electric motor actuator of claim 13, wherein theshaft is engaged by the wrap spring in response to the micro-motor beingenergized.
 15. The electric motor actuator of claim 10, wherein themicro-motor comprises a gear train.
 16. The electric motor actuator ofclaim 15, wherein the gear train operatively couples to the pinion gear.17. An electric motor actuator, comprising: a shaft; a shaft support,the shaft being installed within the shaft support; a second gearinstalled on the shaft; a first gear configured to operatively engagethe second gear; a motor configured to drive the first gear, wherein inresponse to the motor being energized, the first gear drives the secondgear causing the shaft to bind with the shaft support.
 18. The electricmotor actuator of claim 17, wherein the first gear is a pinion gear andthe second gear is a sector gear.
 19. The electric motor actuator ofclaim 17, wherein the second gear is a sector gear that is a cam and isconfigured to exert a radial force on the shaft.
 20. The electric motoractuator of claim 17, wherein the motor comprises a gear train and thegear train is operatively coupled to the first gear, and wherein a gearratio associated with the gear train and the first gear is approximately90:1 to 450:1.